Roller forming die



p 11, 1962 L. A. M NAUGHTON ET AL 3,053,304

ROLLER FORMING DIE Filed Aug. 31, 1959 3 Sheets-Sheet 1 IN VENTORS ATTORNEY Sept. 11, 962 L. A. M NAUGHTON ET AL 3,053,304

ROLLER FORMING DIE 3 Sheets-Sheet 2 Filed Aug. 31, 1959 Sept. 11, 1962 A. M NAUGHTON ET AL 3,053,304

ROLLER FORMING DIE Filed Au 51, 1959 s Sheets-Sheet 3 Z WW %-1? k L Zfl 2 W/mm me .ATTORNEY IN VEN TORS [6X47 ma M trite The invention relates to a forming die and more particularly to one in which a roller is utilized to obtain the desired forming action. Dies embodying the invention are particularly useful in the manufacture of molding strips and similar products in which an end of the strip is to be closed by a plane section integrally formed with the remaining portion of the molding strip. In order to accomplish this in a satisfactory manner, production considerations require that the closed end be formed without forming marks, scratches, distortions or recoil marks. Dies embodying the invention utilize a hardened steel roller mounted in a bronze forming insert. Other materials having similar characteristics may also be used. The insert is preshaped so that it performs a first forming operation on an end of a molding strip and the roller follows the preforming action to provide the roller forming action. A holding die set for the strip holds the strip in place during these actions.

In the drawings:

FIGURE 1 is an end view of a die set embodying the invention and having parts broken away and in section.

FIGURE 2 is a cross section view of the die set taken in the direction of arrows 22 of FIGURE 1 and shows the die set at the completion of the roller forming step.

FIGURE 3 is a view similar to that of FIGURE 2 and shows the die set in position prior to the roller forming step.

FIGURE 4 is an isometric view of the forming insert used in the die set of FIGURE 1.

FIGURE 5 is a cross section view taken in the direction of arrows 55 of FIGURE 2.

FIGURE 6 is an enlarged cross section view of a portion of the die set as shown in FIGURE 5, with parts broken away.

FIGURE 7 is an isometric view of a molding strip having one end closed by the die set.

The molding strip or Work piece 10 is formed to the desired cross section prior to being inserted in the roller forming die set 12 in which the invention is embodied. The strip lit is placed in the die and the end roller-forming operation is performed. The die set '12 is mounted between a die shoe l4 and a punch shoe vl6 in a press of any suitable type. The die set 12 includes a punch section 18 and a die section 20. Each of these sections is divided into a holding section and a forming section. The holding die 22 has its upper surface formed so that it will lit in a complementary manner into the interior of the molding strip 10. The holding punch 24 is formed to fit the outer surface of the molding strip 10 so that the strip may be clamped between the holding die 22 and the holding punch 24. A holding punch mount 26 has the punch 24 secured to its lower surface. The mount and punch are retained in position by punch holding plate 28 which is attached to the punch plate 30. The punch plate in turn is attached to the mounting plate 32. Holding springs 34 are received within mounting plate 32, punch plate 30, and holding punch mount 26 so that mount 26 and punch 24 are urged downwardly against the molding strip 10.

The forming die element 36 is attached to one end of holding die 22 and has its upper surface formed to conform to the interior of the molding 10. It in effect protire vides an extension of the holding die 22. The forming insert 38 is reciprocably received within the guide block 46) and is controlled in its movement by the guide 42. Guide 42 has its upper end 44 shaped to the interior of the molding strip 10 in a manner similar to that of holding die 22. Insert 38 has the lower edge thereof shaped to fit the upper surface of the molding 10' similar to that of the holding punch 24. As is best seen in FIGURE 4, the insert 38 is preferably provided with identical upper and lower surfaces 45, 46. Each surface thus provides a pair of forming edges such as the edges 47, 48. In the position illustrated, forming edge 47 is the edge which will contact molding 10 during the operation of the die. When this edge is worn, however, the insert 38 may be either turned over or reversed to bring another of the forming edges into working position. Thus a single insert has four forming edges which may be used before replacement is required.

The insert 38 has a pair of roller passages 50 and 52 which are provided in insert 38 and a roller 54 extends through one of the passages. Roller 54 is preferably formed of hardened steel. Each of the passages 50 and 52 are provided in insert 38 so that an arcuate portion of the passage is cut out by virtue of the indented face 56 and a similar indented face on the opposite side of the insert. The roller 54 extends through this arcuately cut out section so that it is engageable with the molding strip 10 for proper operation. The roller is mounted in either passage 50 or 52, depending upon the forming edge to be used. Hardened steel roller retaining blocks 58 and 6% are attached to the insert 38 and receive the reduced ends of the roller 54 so that the forming section of the roller does not injure the relatively soft insert. The insert may be made of a suitable material such as bronze.

The insert 38 is removably supported in the guide slot 62 formed in the block 40. The block 40 is attached to the punch plate 30 which is in turn attached to the mounting plate 32. These elements reciprocate with the punch shoe 16 of the press in 'WhiCh the die is installed. The guide block 40 engages the guide 64 which is secured to the guide mount 66. Mount 66 is in turn secured to the base 68 on which the holding die is mounted and in which the guide 42 reciprocates. The base 68 is attached to the shoe 14.

In operation of the die, the molding strip 10' is furnished in lengths such that an end portion 70 may be I utilized to form the enclosed end 72. The molding strip is inserted between the holding punch 24 and the holding die 22 while the shoe 16 is held in its uppermost posi tion. The end 70 of the strip extends over the upper end 44 of the guide 42 and is retained thereby as is seen in FIGURE 3. The press is then moved downwardly so that the holding punch 24 engages the upper surface of the molding 10. The springs 34 then are compressed by continued downward movement of the punch shoe 16. The drive block 40 moves downwardly' and a hardened insert 74 which is provided in the upper end of the guide slot 62 engages the insert 38. The lower surface of insert 38 engages the molding strip end 70. Continued downward movement of the punch shoe 16 along with guide block 40 forces forming insert 38 to bend strip end 74 around the edge of the forming die 36. An air pad or space 76 is provided between the surface of forming die 36 and the adjacent surface of the upper end 44 of the retaining pin 42 as well as between the forming die 36 and the face 56 of insert 38. This space permits the strip end 70 to be bent downwardly without pinching, tearing, or otherwise injuring it. The thickness of space 76 is preferably slightly greater than the thickness of the material from which the molding strip is formed. Due to the construction of insert 38 as described above, roller 54 extends slightly into the air pad volume and the outer surface of the roller is spaced from the insert 38 a distance approximately equal to the thickness of the work piece or strip end 70. As the punch portion of the die continues in its downward movement roller 54 engages the end of the molding strip and provides the finished rolling action required to form the closed end 72. In other words, as the guide block 40 is moved downwardly past the guide 64, the lower surface of the insert 38 is first engaged with the top surface of the strip end 70 to bend the strip end around the die plate 36. As the insert is moved downwardly, the roller 54 subsequently engages the upper surface of the strip end to apply a final finishing bending force. In this manner, the strip end 70 is transversely bent as a result of a bending force applied through the lower surface of the insert 38 during an initial portion of the bending cycle and by a bending force applied through the roller during the final portion of the bending cycle. The press action is then reversed and the forming strip is removed.

A die has thus been provided which will roll an enclosed end on a channel type molding strip without tearing the molding or otherwise damaging it. The portions of the die which wear out quickly are readily replaceable and the forming insert provides four forming edges which may be used consecutively so that a greater overall life of the insert is provided. The die in operation provides a holding step in which the molding is retained in place, after which a preliminary forming operation is performed. The preliminary forming operation is followed by the final roll forming operation. The holding step is then terminated and the finished workpiece is removed.

What is claimed is:

1. In a forming die for providing a closed end on a molding strip, a strip holding die set and a strip end forming die set adjacent said holding die set, said strip holding die set comprising a lower die section and an upper die section formed complementary to the molding strip to hold the strip therebetween, said strip end forming die set comprising a forming die secured to said strip holding die set lower section, a guide block and a forming insert in said guide block and an insert guide, said guide block being moved downwardly to bring said forming insert into forming contact with the end of the molding strip held by said strip holding die set to form the end of the strip about said forming die.

2. A forming die set for providing a closed end on a channel type molding strip, said set comprising a strip holding section and a strip end forming section, said strip end forming section including a forming die and a forming insert mounted for reciprocation relative to said forming die, said forming insert having a forming edge providing a preliminary strip end forming operation and a roller providing a final strip end forming operation.

3. A die set for forming a closed end on a channel type molding strip, said die set including a die shoe and a punch shoe, a die base mounted on said die shoe, a holding die secured to said die base and having the upper surface thereof formed in complementary relation to the interior of a molding strip to be formed by the die, a mounting plate secured to said punch shoe, a punch plate secured to said mounting plate and having a holding plate secured thereto, a holding punch and a holding punch mount received and maintained in position on said punch plate by said holding plate and guided for reciprocation relative to said punch plate by said holding plate, spring means urging said holding punch mount and said holding punch away from said punch plate, a guide block secured to said punch plate and guide means secured to said die base and guiding said guide block during reciprocating movement of the punch portion of the die set, a forming insert received within said guide block and having a forming edge provided thereon and an indented face and a forming roller received through said insert with an arcuate portion thereof extending outwardly of said indented face, a forming die secured to said holding die, an insert guide received in said die base and having an upper end thereof adjacent but spaced from said forming die and engageable with said insert, said insert indented face and said guide and said forming die defining an air pad therebetween, said holding punch engaging a molding to be formed and holding said molding between said punch and said die during the downward stroke of said punch shoe, said insert forming edge engaging the molding strip being formed adjacent one end thereof and bending the molding strip end into said air pad, said insert roller then engaging the molding strip end to finish forming an enclosed end on the molding strip.

4. A forming insert for a forming die set, said insert comprising a forming block having two opposite surfaces thereof each providing a pair of forming edges and two additional opposite sides each providing an indented face, said insert having passages formed therethrough adjacent and arcuately intersecting said faces, and a forming roller extending through one of said passages to extend arcuately outward of one of said indented faces.

5. A forming die set for forming a transverse end section on a work piece having a sinuous cross-sectional configuration, and comprising, an upper work piece clamping block, a lower surface provided on said upper clamping block and being configured to match the upper surface of said work piece, a lower work piece clamping block, an upper surface provided on said lower clamping block and being configured to match the lower surface of said work piece, said upper clamping block and said lower clamping block being vertically aligned to clamp said work piece therebetween, an anvil-type forming insert, said anvil-type forming insert being removably secured to a side surface of said lower clamping block and having an upper surface configured to match the lower surface of said work piece, said upper surface of said anvil-type forming insert being aligned with the upper surface of said lower clamping block, a portion of said upper clamping block including said lower surface thereof extending longitudinally beyond said forming insert a distance approximately equal to the thickness of said work piece, means to force said upper clamping block toward said lower clamping block to fixedly secure said work piece therebetween with said end section extending outwardly beyond said portion of said upper clamping block, a punch-type insert slidably supported adjacent to said anvil-type forming insert and said portion of said upper clamping block and being spaced from said anvil-type insert a distance greater than the thickness of said end section of said work piece, a lower surface of said punch-type insert being configured to match the upper surface of said work piece, guide means to control a bending cycle of movement of said punchtype forming insert from an open position above the outwardly extending end section of said work piece to a forming position below said work piece and adjacent said anvil-type insert, a transverse roller seat formed in said punch-type insert, a roller member rotatably seated in said roller seat and extending outwardly from said punchtype insert toward said anvil-type insert a distance defining a space in said forming position between the outer surface of said roller member and said anvil-type insert approximately equal to the thickness of said end section of said Work piece, and power means to actuate said punch-type insert from said open position to said forming position whereby the lower surface of said punchtype insert is first engaged with the top surface of said end section of said work piece and subsequently said roller member is engaged with said end section of said work piece so that in said forming position said end section of said work piece is transversely bent as a result of a bending force applied by said punch-type insert through said lower surface thereof during an initial portion of the bending cycle and through said roller memher during the final portion of the bending cycle.

6. A die set for forming a flat transverse end section on a work piece having a sinuous cross-section, and comprising work piece holding means, an anvil-type forming insert, a punch-type forming insert, guide means formed adjacent said anvil-type insert, said work piece holding means being adapted to position an end portion of said work piece outwardly over said anvil-type insert, said punch-type insert being movably supported by said guide means and being movable thereby between an open position adjacent said end portion of said work piece and a forming position adjacent said anvil-type insert, drive means connected to said punch-type insert to cause actuation thereof between said open position and said forming position, a roller member secured to said punch-type insert and movable therewith, said punch-type insert having a first surface contoured to match the adjacent surface of said endportion of said work piece in said open position, said punch-type insert having a side surface transverse to said first surface spaced closely adjacent said anvil-type insert and intersecting said first surface of said punch-type insert to form a bending edge, said roller member being rotatably secured to said punch-type insert and intersecting said side surface and spaced from said bending edge and extending outwardly beyond said side surface toward said anvil-type insert and spaced therefrom in said forming position a distance approximately equal to the thickness of said end portion of said work piece, power means connected to said drive means to force said punch-type insert from said open position to said forming position to cause in sequence said bending edge to engage and bend said end portion of said work piece around said anvil-type insert and subsequently to cause said roller member to engage said end portion of said work piece to further bend said end portion to a transverse position relative to said work piece between said anvil-type insert and said punch-type insert.

7. The die set as defined in claim 6 and wherein said punch-type insert is provided with a second surface contoured to match the adjacent surface of said end portion of said work piece in the open position, said punch-type insert being formed with another side surface opposite the aforementioned side surface and identical thereto, a roller member seat formed in said punch-type insert and intersecting said other side surface and adapted to retain said roller member in a position identical to the position of said roller member relative to the first mentioned side surface, and said other side surface and said first mentioned side surface intersecting said first surface and said second surface to form identical bending edges whereby said punch-type insert may be indexed relative to said punch-type insert to provide a plurality of identical edge and roller member forming combinations.

8. A die set for forming a flat transverse end section on a work piece having a sinuous cross-section, and comprising a punch plate, a die plate, a pair of spaced guide members fastened to said punch plate and extending therefrom, a holding member guide way formed between said guide members, a first holding member slidably supported within said guide way, another holding member supported by said die plate and aligned with the first holding member, said first holding member and said other holding member having adjacent surfaces contoured to match opposite side surfaces of said work piece, an anvil-type forming insert secured to said other holding member, said anviltype insert having an end surface contoured to match said other holding member, said end surface of said anvil-type insert being aligned with and forming a continuation of the contoured surface of said other holding member, a punch guide Way formed between said first holding member and said anvil-type insert and a side surface of one of said guide members, power means to clamp a Work piece between said first holding member and said other holding member with an end portion extending therefrom outward- Q ly beyond said anvil-type insert toward said one of said guide members, said side surface of said one of said guide members being spaced from said anvil-type insert a distance greater than the length of said portion of said work piece so that said portion of said work piece is positionable within said guide Way by said holding members, a punchtype forming insert mounted in said punch guide way and movably connected to said one guide member, said punchtype insert having an end surface contoured to match the contoured surface of said first holding member, said end surface of said punch-type insert being aligned with and forming a continuation of the contoured surface of said first holding member and being engageable with the adjacent surface of said portion of said work piece, and power means to actuate said punch-type insert from a normal position with the contoured end surface thereof substantially parallel to the adjacent surface of said portion of said Work piece to a forming position with the contoured end surface thereof substantially normal to the adjacent surface of said portion of said work piece by bending said portion around said anvil-type insert.

9. The die set as defined in claim 8 and having a movable guide member aligned with said punch-type insert, said guide member having an end surface contoured to match the contoured surfaces of said other holding member and said anvil-type insert, and said contoured surface of said guide member being engageable with the adjacent corre sponding surface of said portion of said work piece opposite said punch-type insert in the normal position.

10. A die set for forming a transverse end section on a work piece having a sinuous cross-section and comprising, a punch plate, a die plate normally spaced from said punch plate in an open position relative thereto, power means to force said punch plate and said die plate toward one another to a closed bending position, a punch insert drive block connected to said punch plate, drive block guide means fixed to said die plate, a forming die fixed to said guide plate and spaced from said guide block means to provide a cavity to accommodate said punch insert drive block therebetween When said punch plate and said guide plate are in the closed bending position, a punch insert secured to said punch insert drive block and cooperably aligned with said forming die, said punch insert being spaced closely adjacent said forming die between said forming die and said guide means in the closed bending position, said punch insert being spaced above said forming die in said open position, work piece holding means to secure a Work piece and to position a portion thereof in a working position extending over said forming die and extending under said punch insert, said punch insert having a contoured surface extending substantially parallel to said portion of said work piece in said working position, said surface of said punch insert being contoured to match the adjacent surface of said portion of said work piece, said forming die having a contoured surface extending substantially parallel to said portion of said work piece in said Working position, said forming die surface being contoured to match the adjacent surface of said work piece in the working position, said punch insert being spaced from said forming die in said closed position a distance approximately equal to the thickness of said portion of said work piece so that said portion of said Work piece will be transversely bent from a position substantially parallel to the contoured surface of said punch insert to a bent position substantially transverse to said contoured surface of said punch insert as said punch insert is moved from said open position to said bending position.

11. The die set as defined in claim 10 and wherein said punch insert comprises a side surface spaced adjacent said forming die in said closed position and intersecting said contoured surface of said punch insert to form a bending edge, a roller member supported by said punch insert and intersecting said side surface and said roller member having a portion extending outwardly from said side surface and being engageable With said portion of said work piece in said bent position whereby the transversely bent portion of said work piece is formed in sequence during movement from said open position to said closed bending position by forming engagement of said portion of said work piece with said bending edge and subsequently with said roller member.

12. A die set for forming a flat transverse end section on a work piece having a preformed cross-section, and comprising work piece holding means, an anvil-type insert, a punch-type insert, guide means formed adjacent said anvil-type insert, said work piece holding means being adapted to position an end portion of said work piece outwardly over said anvil-type insert, said punch-type insert being movably supported by said guide means and being movable thereby between an open position adjacent said end portion of said work piece and a forming position, drive means associated with said punch-type insert to cause actuation thereof between said open position and said forming position, a roller member secured to said punch-type insert and movable therewith, said punchtype insert having a first surface contoured to engage the adjacent surface of said end portion of said work piece in said rest position, said punch-type insert having a side surface transverse to said first surface spaced closely adjacent said anvil-type insert and intersecting said first surface of said punch-type insert to form a bending edge, said roller member being secured to said surface of said punch-type insert and spaced from said bending edge and extending outwardly beyond said side surface toward said anvil-type insert and spaced therefrom in said forming position a distance approximately equal to the thickness of said end portion of said work piece, power means connected to said drive means to force said punch-type insert from said open position to said forming position to cause in sequence" said bending edge to engage and bend said end portion of said work piece around said anvil-type insert and subsequently to cause said roller member to engage said end portion of said work piece to further bend said end portion to a transverse position relative to said work piece between said anvil-type insert and said punchtype insert.

13. The die set as defined in claim 12 and wherein said punch insert comprises a central 'body portion of relatively soft material, said first surface and said forming edge being formed on said body portion, a pair of support plates of relatively hard material, and said body portion being secured between said support plates to provide a unitary punch insert.

14. The die set as defined in claim 12 and wherein said punch-type insert is provided with a second surface contoured to engage the adjacent surface of said end portion of said work piece in the open position, said punch-type insert being formed with another side surface opposite the aforementioned side surface and identical thereto, a roller member seat formed in said punchtype insert and intersecting said other side surface and adapted to retain said roller member in a position identical to the position of said roller member relative to the first mentioned side surface, and said other side surface and said first mentioned side surface intersecting said first surface and said second surface to form identical bending edges whereby said punch-type insert may be indexed to provide a plurality of identical edge and roller member forming combinations.

References Cited in the file of this patent UNITED STATES PATENTS 419,156 McGiehan Jan. 2, 1890 625,789 Macbeth May 30, 1899 1,052,069 Lassister Feb. 4, 1913 2,091,749 Christman Aug. 31, 1937 2,301,643 Sachse et a1. Nov. 10, 1942 2,339,032 Schlenzig Ian. 11, 1944 2,400,004 Jager May 7, 1946 2,460,951 Schufi? Feb. 8, 1949 2,481,518 Johnson Sept. 13, 1949 2,771,670 Ruppert Nov. 27, 1956 

